Submerged arc welding (SAW) is a common arc welding process.

The first patent on the

submerged-arc welding (SAW) process was taken out in 1935 and covered an electric arc
beneath a bed of granulated flux. Originally developed and patented by Jones, Kennedy and
Rothermund, the process requires a continuously fed consumable solid or tubular (metal cored)
electrode.[1] The molten weld and the arc zone are protected from atmospheric contamination by
being "submerged" under a blanket of granular fusible flux consisting of lime, silica, manganese
oxide, calcium fluoride, and other compounds. When molten, the flux becomes conductive, and
provides a current path between the electrode and the work. This thick layer of flux completely
covers the molten metal thus preventing spatter and sparks as well as suppressing the intense
ultraviolet radiation and fumes that are a part of the shielded metal arc welding (SMAW)
process.
SAW is normally operated in the automatic or mechanized mode, however, semi-automatic
(hand-held) SAW guns with pressurized or gravity flux feed delivery are available. The process
is normally limited to the flat or horizontal-fillet welding positions (although horizontal groove
position welds have been done with a special arrangement to support the flux). Deposition rates
approaching 45 kg/h (100 lb/h) have been reported this compares to ~5 kg/h (10 lb/h) (max)
for shielded metal arc welding. Although currents ranging from 300 to 2000 A are commonly
utilized,[2] currents of up to 5000 A have also been used (multiple arcs).
Single or multiple (2 to 5) electrode wire variations of the process exist. SAW strip-cladding
utilizes a flat strip electrode (e.g. 60 mm wide x 0.5 mm thick). DC or AC power can be used,
and combinations of DC and AC are common on multiple electrode systems. Constant voltage
welding power supplies are most commonly used; however, constant current systems in
combination with a voltage sensing wire-feeder are available.

Welding head
It feeds flux and filler metal to the welding joint. Electrode (filler metal) gets energized here.

Flux hopper
It stores the flux and controls the rate of flux deposition on the welding joint.

Flux
The granulated flux shields and thus protects molten weld from atmospheric contamination. The
flux cleans weld metal and can modify its chemical composition also. The flux is granulated to a
definite size. It may be of fused, bonded or mechanically mixed type. The flux may consist of
fluorides of calcium and oxides of calcium, magnesium, silicon, aluminium and manganese.

Alloying elements may be added as per requirements. Substances evolving large amount of gases
during welding are never mixed with the flux. Flux with fine and coarse particle sizes are
recommended for welding heavier and smaller thickness respectively.

Electrode
SAW filler material usually is a standard wire as well as other special forms. This wire normally
has a thickness of 1.6 mm to 6 mm (1/16 in. to 1/4 in.). In certain circumstances, twisted wire
can be used to give the arc an oscillating movement. This helps fuse the toe of the weld to the
base metal.[3] The electrode composition depends upon the material being welded. Alloying
elements may be added in the electrodes. Electrodes are available to weld mild steels, high
carbon steels, low and special alloy steels, stainless steel and some of the nonferrous of copper
and nickel. Electrodes are generally copper coated to prevent rusting and to increase their
electrical conductivity. Electrodes are available in straight lengths and coils. Their diameters may
be 1.6, 2.0, 2.4, 3, 4.0, 4.8, and 6.4 mm. The approximate value of currents to weld with 1.6, 3.2
and 6.4 mm diameter electrodes are 150350, 250800 and 6501350 Amps respectively.

Welding Operation
The flux starts depositing on the joint to be welded. Since the flux when cold is non-conductor of
electricity, the arc may be struck either by touching the electrode with the job or by placing steel
wool between electrode and job before switching on the welding current or by using a high
frequency unit. In all cases the arc is struck under a cover of flux. Flux otherwise is an insulator
but once it melts due to heat of the arc, it becomes highly conductive and hence the current flow
is maintained between the electrode and the workpiece through the molten flux. The upper
portion of the flux, in contact with atmosphere, which is visible remains granular (unchanged)
and can be reused. The lower, melted flux becomes slag, which is waste material and must be
removed after welding.
The electrode at a predetermined speed is continuously fed to the joint to be welded. In semiautomatic welding sets the welding head is moved manually along the joint. In automatic
welding a separate drive moves either the welding head over the stationary job or the job
moves/rotates under the stationary welding head.
The arc length is kept constant by using the principle of a self-adjusting arc. If the arc length
decreases, arc voltage will increase, arc current and therefore burn-off rate will increase thereby
causing the arc to lengthen. The reverse occurs if the arc length increases more than the normal.
[citation needed]

A backing plate of steel or copper may be used to control penetration and to support large
amounts of molten metal associated with the process.

Key SAW process variables

Wire feed speed (main factor in welding current control)

Arc voltage

Travel speed

Electrode stick-out (ESO) or contact tip to work (CTTW)

Polarity and current type (AC or DC) and variable balance AC current

Material applications

Carbon steels (structural and vessel construction)

Low alloy steels

Stainless steels

Nickel-based alloys

Surfacing applications (wear-facing, build-up, and corrosion resistant overlay of steels)

Advantages

High deposition rates (over 45 kg/h (100 lb/h) have been reported).

High operating factors in mechanized applications.

Deep weld penetration.

Sound welds are readily made (with good process design and control).

High speed welding of thin sheet steels up to 5 m/min (16 ft/min) is possible.

Minimal welding fume or arc light is emitted.

Practically no edge preparation is necessary depending on joint configuration and

required penetration.

The process is suitable for both indoor and outdoor works.

Welds produced are sound, uniform, ductile, corrosion resistant and have good impact
value.

Single pass welds can be made in thick plates with normal equipment.

The arc is always covered under a blanket of flux, thus there is no chance of spatter of
weld.

50% to 90% of the flux is recoverable, recycled and reused.[4]